Coated abrasive film belt

ABSTRACT

The present invention relates generally to coated abrasive articles, such as coated abrasive film belts having improved strength and durability, as well as methods of making and using said coated abrasive articles.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119(e) to U.S. PatentApplication No. 62/786,752, entitled “Coated Abrasive Film Belt,” byPaul S. GOLDSMITH, filed Dec. 31, 2018, which is assigned to the currentassignee hereof and incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to coated abrasive articles,such as coated abrasive film belts having improved strength anddurability, as well as methods of making and using said coated abrasivearticles.

BACKGROUND

Abrasive articles, such as coated abrasives, are used in variousindustries to machine work pieces, such as by lapping, grinding, andpolishing. Surface processing using abrasive articles spans a wideindustrial scope from initial coarse material removal to high precisionfinishing and polishing of surfaces at a submicron level.

Effective and efficient abrasion of high performance metal, ceramic, andcermet industrial parts, such as drill bit components and aircraftengine parts, pose numerous processing challenges.

Industries that produce such parts are sensitive to factors thatinfluence operational costs, including the speed at which a surface canbe prepared, the cost of the materials used to prepare that surface, andthe costs associated with the time expended to prepare a surface.

Therefore, there continues to be a demand for improved abrasive productsand methods that can offer enhanced abrasive processing performance,efficiency, and improved surface quality.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 is an illustration of cross-sectional view of an embodiment of acoated abrasive film belt including a joint.

FIG. 2 is an illustration of a top view of a coated abrasive film beltincluding a joint.

FIG. 3 is a flowchart of an embodiment of a method of making a coatedabrasive film.

FIG. 4 is a flowchart of an embodiment of a method of making a coatedabrasive film into a coated abrasive film belt.

FIG. 5 is a chart providing comparative data of workpiece processingamounts of conventional abrasive articles and other embodiments ofabrasive articles of the disclosure.

FIG. 6 is a chart providing comparative data of workpiece processingamounts for conventional abrasive articles and other embodiments ofabrasive articles of the disclosure.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

The following description, in combination with the figures, is providedto assist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This discussion is provided to assist in describing theteachings and should not be interpreted as a limitation on the scope orapplicability of the teachings.

The term “averaged,” when referring to a value, is intended to mean anaverage, a geometric mean, or a median value. As used herein, the terms“comprises,” “comprising,” “includes,” “including,” “has,” “having,” orany other variation thereof, are intended to cover a non-exclusiveinclusion. For example, a process, method, article, or apparatus thatcomprises a list of features is not necessarily limited only to thosefeatures but can include other features not expressly listed or inherentto such process, method, article, or apparatus. As used herein, thephrase “consists essentially of” or “consisting essentially of” meansthat the subject that the phrase describes does not include any othercomponents that substantially affect the property of the subject.

Further, unless expressly stated to the contrary, “or” refers to aninclusive-or and not to an exclusive-or. For example, a condition A or Bis satisfied by any one of the following: A is true (or present) and Bis false (or not present), A is false (or not present) and B is true (orpresent), and both A and B are true (or present).

The use of “a” or “an” is employed to describe elements and componentsdescribed herein. This is done merely for convenience and to give ageneral sense of the scope of the invention. This description should beread to include one or at least one and the singular also includes theplural, or vice versa, unless it is clear that it is meant otherwise.

Further, references to values stated in ranges include each and everyvalue within that range. When the terms “about” or “approximately”precede a numerical value, such as when describing a numerical range, itis intended that the exact numerical value is also included. Forexample, a numerical range beginning at “about 25” is intended to alsoinclude a range that begins at exactly 25. Moreover, it will beappreciated that references to values stated as “at least about,”“greater than,” “less than,” or “not greater than” can include a rangeof any minimum or maximum value noted therein.

As used herein, the phrase “average particle diameter” can be referenceto an average, mean, or median particle diameter, also commonly referredto in the art as D50.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and can be found in textbooks andother sources within the coated abrasive arts.

Coated Abrasive Article

FIG. 1 shows an illustration of a cross section of a coated abrasivebelt 100 embodiment. As shown in FIG. 1 , the coated abrasive belt cancomprise an abrasive film including a joint, such as a butt joint. Theabrasive film can comprise an abrasive layer 103 disposed on a backingmaterial 101 (also called herein a “backing”). The backing material 101can comprise a backing substrate 105 having a first major surface 109and a second major surface 107, wherein a layer of a polymeric frontcoat composition 111 (also called herein a “front coat”) is disposed onthe first major surface 109 of the backing substrate, and wherein alayer of polymeric back coat composition 113 (also called herein a “backcoat”) is disposed on the second major surface 107 of the backingsubstrate. The abrasive layer can include a plurality of abrasiveparticles 117 dispersed on or in a layer of polymeric binder composition115 (also called herein a “make coat”). The layer of polymeric bindercomposition 115 can be disposed in direct contact with the polymericfront coat composition 111. A layer of polymeric size coat composition119 (also called herein a “size coat”) can be disposed over thepolymeric binder composition 115 and abrasive particles 117. Further, anoptional layer of polymeric supersize coat composition (not shown) canbe disposed over the size coat composition 119. The joint 125 cancomprise a first end 127 of the abrasive film abutting a second end 129of the abrasive film, a layer of polymeric joint adhesive 121 disposedon the back coat 113 of the first end 127 and the back coat 113 of thesecond end 129, and a joint tape 123 disposed over the polymeric jointadhesive 121.

FIG. 2 shows an illustration of a top view of a coated abrasive belt 200embodiment. As shown in FIG. 2 , the coated abrasive belt 200 caninclude a joint 225. The joint 225, such as a butt joint, can include afirst end 227 of the abrasive film that is abutting a second end 229 ofthe abrasive film. A region 231 adjacent the joint 225, can be surfacetreated, such as by a corona treatment or other surface energytreatment. In region 231, a polymeric joint adhesive can be disposed onthe underside of the abrasive film that is in contact with the back coaton the first end 227 and the back coat on the second end 229. A jointtape can be disposed overlying the polymeric joint adhesive. Abrasiveparticles 217 can be disposed in an abrasive layer 203, which is theworking surface (also called herein the “abrasive surface” or “topsurface”) of the abrasive article.

FIG. 3 is an illustration of a flowchart of an embodiment of a method300 of making a coated abrasive film. Step 302 includes disposing alayer of a polymeric front coat composition (also called herein a “frontcoat”) on a first major surface of a backing substrate. Step 304includes disposing a layer of a polymeric back coat composition (alsocalled herein a “back coat”) on a second major surface of the backingsubstrate. In an embodiment, step 302 and step 304 can be accomplishedat the same time. In another embodiment, step 302 and step 304 can beaccomplished separately. Step 306 includes disposing a layer of apolymeric make coat composition (also called herein a “make coat”) onthe front coat. Step 308 includes disposing a plurality of abrasiveparticles on or in the make coat. Step 310 includes disposing apolymeric size coat composition (also called herein a “size coat”) overthe abrasive particles and the make coat to form a coated abrasive film.The coated abrasive film can be used as a polishing film, formed into anabrasive belt (polishing belt), or converted (i.e., cut) into differentshapes, such as discs, sheets, or other shapes.

FIG. 4 is an illustration of a flowchart of an embodiment of a method400 of making an abrasive belt from the abrasive film produced by method300. Step 402 includes bringing a first end of the abrasive film intocontact with a second end of the abrasive film to form a joint such thatthe first end and the second end abut each other and the abrasive filmforms a loop. Step 404 includes disposing a joint adhesive on the backcoat of the first end and the second end in a region adjacent the joint.Step 406 includes disposing a joint tape over the joint adhesive. Step408 includes applying pressure and heat to adhere the joint tape andcure the joint adhesive.

Backing Material

As previously stated, the backing material 101 (“backing”) comprises abacking substrate 105 having a first major surface 109 (“first side”)and a second major surface 107 (“second side”), wherein a layer of apolymeric front coat composition 111 (also called herein a “front coat”)is disposed on the first major surface 109 of the backing substrate, andwherein a layer of polymeric back coat composition 113 (also calledherein a “back coat”) is disposed on the second major surface 107 of thebacking substrate. In an embodiment, the backing material 101 can bebeneficially flexible but also is resistant to curling and lays flatwhen at rest. The backing material 101 can comprise a proper combinationof desired physical, chemical, mechanical, and/or performance propertiesand/or features to produce advantageous abrasive performance incombination with abrasive particles as described in greater detailherein.

Backing Substrate

The backing substrate can comprise a polymeric film, such as polyolefinfilm (e.g., polypropylene including biaxially oriented polypropylene), apolyester film (e.g., polyethylene terephthalate), a polyamide film, ora cellulose ester film; a metal foil; a mesh; a foam (e.g., naturalsponge material or polyurethane foam); a cloth (e.g., cloth made fromfibers or yarns comprising polyester, nylon, silk, cotton, poly-cotton,rayon, or combinations thereof); a paper; a vulcanized paper; avulcanized rubber; a vulcanized fiber; a nonwoven material; acombination thereof. In an embodiment, the polymeric film can be asurface energy modified film, such as a primed film, a corona treatedfilm, a plasma treated film, a chemically treated film, or a combinationthereof. In a specific example, the backing substrate can comprise apolyester film that has been chemically primed and corona treated orplasma treated. Suitable chemical primers can include imide typeprimers, such as polyethylene imine, and the like.

The backing substrate can have a surface energy in a beneficial range.In an embodiment, the surface energy of the film can be not less than 5dyne/cm², such as at least 10 dyne/cm², at least 20 dyne/cm², at least30 dyne/cm², at least 40 dyne/cm², at least 45 dyne/cm² or at least 50dyne/cm². In an embodiment, the surface energy can be not greater than100 dyne/cm², such as not greater than 90 dyne/cm², not greater than 80dyne/cm², not greater than 70 dyne/cm², not greater than 65 dyne/cm², ornot greater than 60 dyne/cm². The amount of surface energy can be withina range comprising any pair of the previous upper and lower limits. Inan embodiment, the polymeric film can have an amount of surface energynot less than 5 dyne/cm² to not greater than 100 dyne/cm², such as 20dyne/cm² to 90 dyne/cm², such as 30 dyne/cm² to 80 dyne/cm², such as 40dyne/cm² to 70 dyne/cm², or 50 dyne/cm² to 60 dyne/cm².

The backing substrate can have a thickness in a beneficial range. In anembodiment, the thickness of the film can be not less than 1 mil, suchas at least 2 mil, at least 2.5 mil, at least 3 mil, at least 3.5 mil,at least 4 mil, or at least 4.5 mil. In an embodiment, the thickness canbe not greater than 9 mil, such as not greater than 8 mil, not greaterthan 7.5 mil, not greater than 7 mil, not greater than 6.5 mil, or notgreater than 6 mil. The amount of thickness can be within a rangecomprising any pair of the previous upper and lower limits. In anembodiment, the polymeric film can have an amount of thickness not lessthan 1 mil to not greater than 9 mil, such as 2 mil to 8 mil, such as2.5 mil to 7.5 mil, such as 3 mil to 7 mil, or 50 mil to 60 mil.

Front Coat

In an embodiment, a layer of a polymeric front coat composition 111 (a“front coat”) is disposed on the first major surface 109 of the backingsubstrate. In an embodiment, the polymeric front coat composition cancomprise a polyethylene composition. The polyethylene composition cancomprise a low-density polyethylene (LDPE), a linear low-densitypolyethylene (LLDPE), a high-density polyethylene (HDPE), amedium-density polyethylene (HDPE), or an ultra-high-molecular-weightpolyethylene (UHMWPE). In a specific embodiment, the polymeric frontcoat composition comprises a low-density polyethylene.

The front coat can have a thickness in a beneficial range. In anembodiment, the thickness of the film can be not less than 0.25 mil,such as at least 0.5 mil, at least 0.75 mil, at least 1.0 mil, at least1.25 mil, at least 1.5 mil, or at least 1.75 mil. In an embodiment, thethickness can be not greater than 5 mil, such as not greater than 4 mil,not greater than 3.5 mil, not greater than 3 mil, not greater than 2.75mil, or not greater than 2.5 mil. The amount of thickness can be withina range comprising any pair of the previous upper and lower limits. Inan embodiment, the polymeric film can have an amount of thickness notless than 0.25 mil to not greater than 5 mil, such as 1 mil to 3 mil,such as 1.5 mil to 2.5 mil.

Back Coat

In an embodiment, a layer of polymeric back coat composition 113 (a“back coat”) is disposed on the second major surface 107 of the backingsubstrate. In an embodiment, the polymeric back coat composition cancomprise an acrylate composition. The acrylate composition can comprisean ethyl acrylate, an ethylene acrylate, an ethylene-ethyl acrylate(EEA), a methyl acrylate, an ethylene methyl acrylate (EMA) copolymer, abutyl acrylate, a copolymer of ethylene and butyl acrylate (EBA), anethylene acrylic ester terpolymer (i.e., a terpolymer of ethylene,acrylic ester, and maleic anhydride), or a combination thereof. In aspecific embodiment, the back coat composition comprises a mixture of 1)a copolymer of ethylene and butyl acrylate (EBA), and 2) an ethyleneacrylic ester terpolymer (i.e., a terpolymer of ethylene, acrylic ester,and maleic anhydride).

The back coat can have a thickness in a beneficial range. In anembodiment, the thickness of the film can be not less than 0.1 mil, suchas at least 0.2 mil, at least 0.3 mil, at least 0.4 mil, at least 0.5mil, at least 0.6 mil, at least 0.7 mil, or at least 0.8 mil. In anembodiment, the thickness can be not greater than 3 mil, such as notgreater than 2 mil, not greater than 1.8 mil, not greater than 1.7 mil,not greater than 1.6 mil, not greater than 1.5 mil, not greater than 1.4mil, not greater than 1.3 mil, or not greater than 1.2 mil. The amountof thickness can be within a range comprising any pair of the previousupper and lower limits. In an embodiment, the polymeric film can have anamount of thickness not less than 0.1 mil to not greater than 3 mil,such as 0.25 mil to 2.5 mil, such as 0.5 mil to 2 mil.

Belt Joint

In an embodiment, the coated abrasive belt can comprise an abrasive filmincluding a joint (also called herein a “splice”). In an embodiment, thejoint can comprise a lap joint, a butt joint, or a combination thereof.The joint can be reinforced, such as with a tape or other suitablesupporting substrate. The joint can include a joint adhesive. In anembodiment, the joint can be a butt joint that includes a joint tape anda joint adhesive.

In an embodiment, a joint tape can comprise a polymeric film (includingprimed films), such as a polyolefin film (e.g., polyethylene orpolypropylene, including biaxially oriented polypropylene), a polyesterfilm (e.g., polyethylene terephthalate or a liquid crystal polymer), apolyamide film, a cellulose ester film, or any combination thereof; ametal foil; a mesh; a foam (e.g., natural sponge material orpolyurethane foam); a cloth (e.g., cloth made from fibers or yarnscomprising polyester, nylon, silk, cotton, poly-cotton or rayon); apaper; a nonwoven material; or any combination thereof. In specificembodiment, the joint tape can comprise a polymer film such as apolyester film, a polyamide film, a polyaramid film, a polyimide film, apolyolefin, or any combination thereof. In a particular embodiment, thejoint tape can include a polyethylene terephthalate (PET) film.

In an embodiment, a joint adhesive can comprise a polyolefincomposition, a polyamide composition, an acrylic composition, an epoxycomposition, a polyester composition, a polyurethane composition, or acombination thereof. In a specific embodiment, the joint adhesive can bean epoxy composition, a polyester composition, or a polyurethanecomposition.

Abrasive Layer

In an embodiment, the abrasive layer can include a plurality of abrasiveparticles 117 dispersed on or in a layer of polymeric binder 115 (“makecoat”). In an embodiment, the abrasive particles can be blended togetherwith the polymeric binder to form an abrasive slurry wherein theabrasive particles are dispersed throughout the binder formulation.Alternatively, the polymeric binder composition can be coated onto thebacking material and the abrasive particles then applied over the bindercomposition. Optionally, patterns can be formed in the abrasive layer bymolding, pressing, or tooling of the abrasive layer.

Abrasive Particles

Abrasive particles can include alumina, silicon carbide, silica, ceria,and harder, high performance superabrasive particles such as cubic boronnitride and diamond. The abrasive particles can be essentiallysingle-phase inorganic materials, mixed phase materials, or combinationsthereof. Additionally, the abrasive particles can include compositeparticulate materials, such as aggregates, which can be formed throughslurry processing pathways that include removal of the liquid carrierthrough volatilization or evaporation, leaving behind unfired (“green”)aggregates, that can optionally undergo high temperature treatment(i.e., firing, sintering) to form usable, fired aggregates. Further, theabrasive layer can include engineered abrasives includingmacrostructures and particular three-dimensional structures.

The abrasive particles can be formed of any one of or a combination ofabrasive particles, including silica, alumina (ceramic, fused, orsintered), zirconia, zirconia/alumina oxides, silicon carbide, garnet,diamond, cubic boron nitride, silicon nitride, ceria, titanium dioxide,titanium diboride, boron carbide, tin oxide, tungsten carbide, titaniumcarbide, iron oxide, chromia, flint, emery. For example, the abrasiveparticles can be selected from a group consisting of silica, alumina,zirconia, silicon carbide, silicon nitride, boron nitride, garnet,diamond, co-fused alumina zirconia, ceria, titanium diboride, boroncarbide, flint, emery, alumina nitride, and a blend thereof. Particularembodiments have been created by use of abrasive particles comprised ofdiamond.

In an embodiment, the abrasive particles can be diamond particles (alsoreferred to herein as “diamonds”), cubic boron nitride particles, orcombinations thereof. In an embodiment, the abrasive particles comprisediamonds. The diamonds can be monocrystalline, polycrystalline, or acombination thereof. The diamonds can be natural diamonds, syntheticdiamonds, metal-coated diamonds, resin coated diamonds, or combinationsthereof. The abrasive particles can be loose diamonds, diamondagglomerates, diamond aggregates, or a combination thereof.

In specific embodiments, superabrasive particles include cubic boronnitride and diamond particles. These superabrasive particles can benatural (e.g. natural diamond) or synthetic (e.g. cubic boron nitrideand synthetic diamond) products. The superabrasive particles may have ablocky shape associated with them or alternatively, a needle-like shape.The superabrasive particles may be surface coated or not surface coated.In an embodiment, a blend of superabrasive particles and conventionalabrasive particles (e.g. alumina, silicon carbide, ceria, and silica)can be used.

The abrasive particles can have a particular shape, such as a rod, atriangle, a pyramid, a cone, a solid sphere, a hollow sphere, or thelike. Alternatively, the abrasive particles can be randomly shaped.

The abrasive particles can be in a beneficial size range, conform to abeneficial size distribution, or a combination thereof. In anembodiment, the abrasive particles can have an average particle size ofnot less than 1 micron, such as at least 2 micron, at least 3 micron, atleast 5 micron, at least 10 micron, at least 15 micron, at least 20micron, or at least 25 micron. In an embodiment, the average particlesize can be not greater than 500 micron, such as not greater than 400micron, not greater than 300 micron, not greater than 200 micron, notgreater than 150 micron, or not greater than 125 micron. The averageparticle size can be within a range comprising any pair of the previousupper and lower limits. In an embodiment, the abrasive particles canhave an average particle size not less than 5 micron to not greater than250 micron, such as 10 micron to 200 micron, such as 15 micron to 150micron, such as 20 micron to 125 micron.

Binder Composition—Make Coat or Slurry Coat

As stated previously, a layer of polymeric binder composition 115 can bedisposed in direct contact with the polymeric front coat composition111. In a particular aspect, the polymeric binder composition 115 can becomprised of a single polymer or a blend of polymers.

The binder composition can be formed from an epoxy composition, anacrylic composition, a phenolic composition, a polyurethane composition,a urea formaldehyde composition, a polysiloxane composition, orcombinations thereof. In addition, the binder composition can includeactive filler particles, additives, or a combination thereof, asdescribed herein.

The binder composition generally includes a polymer matrix, which bindsabrasive particles to the backing or to a compliant coat, if such acompliant coat is present. Typically, the binder composition is formedof cured binder composition. In an embodiment, the binder compositionincludes a polymer component and a dispersed phase.

The binder composition can include one or more reaction constituents orpolymer constituents for the preparation of a polymer. A polymerconstituent can include a monomeric molecule, a polymeric molecule, or acombination thereof. The binder composition can further comprisecomponents selected from the group consisting of solvents, plasticizers,chain transfer agents, catalysts, stabilizers, dispersants, curingagents, reaction mediators and agents for influencing the fluidity ofthe dispersion.

The polymer constituents can form thermoplastics or thermosets. By wayof example, the polymer constituents can include monomers and resins forthe formation of polyurethane, polyurea, polymerized epoxy, polyester,polyimide, polysiloxanes (silicones), polymerized alkyd,styrene-butadiene rubber, acrylonitrile-butadiene rubber, polybutadiene,or, in general, reactive resins for the production of thermosetpolymers. Another example includes an acrylate or a methacrylate polymerconstituent. The precursor polymer constituents are typically curableorganic material (i.e., a polymer monomer or material capable ofpolymerizing or crosslinking upon exposure to heat or other sources ofenergy, such as electron beam, ultraviolet light, visible light, etc.,or with time upon the addition of a chemical catalyst, moisture, orother agent, which cause the polymer to cure or polymerize). A precursorpolymer constituent example includes a reactive constituent for theformation of an amino polymer or an aminoplast polymer, such asalkylated urea-formaldehyde polymer, melamine-formaldehyde polymer, andalkylated benzoguanamine-formaldehyde polymer; acrylate polymerincluding acrylate and methacrylate polymer, alkyl acrylate, acrylatedepoxy, acrylated urethane, acrylated polyester, acrylated polyether,vinyl ether, acrylated oil, or acrylated silicone; alkyd polymer such asurethane alkyd polymer; polyester polymer; reactive urethane polymer;phenolic polymer such as resole and novolac polymer; phenolic/latexpolymer; epoxy polymer such as bisphenol epoxy polymer; isocyanate;isocyanurate; polysiloxane polymer including alkylalkoxysilane polymer;or reactive vinyl polymer. The binder composition can include a monomer,an oligomer, a polymer, or a combination thereof. In a particularembodiment, the binder composition includes monomers of at least twotypes of polymers that when cured can crosslink.

In an embodiment, the binder composition can include epoxy constituentsand acrylic constituents that when cured form an epoxy/acrylic hybridpolymer. Alternatively, the binder composition can comprise a butylacrylate polymer. In an embodiment, the binder composition can comprisea cycloaliphatic epoxy resin, a di-acrylate resin, or a combinationthereof. In a specific embodiment, the binder composition can comprise ahydrogenated diphenylolpropane (DPP) epoxy resin, an oxetane resin(4-member cyclic ether), a bisphenol A Epoxy Diacrylate resin(diacrylate ester of a bisphenol A epoxy resin), a propoxylatedneopentyl glycol diacrylate resin, or combinations thereof.

Size Coat Layer

As described above, layer of polymeric size coat composition 119 (a“size coat”) can be disposed over the polymeric binder composition 115and abrasive particles 117. The size coat composition 119 can be thesame as or different from the polymeric binder composition 115 of theabrasive layer 103 (i.e., the size coat composition can be the same asor different from the make coat composition). The size coat compositioncan include one or more fillers, additives, or a combination thereof.

In a specific embodiment, the size coat composition 119 can comprise anepoxy resin, an acrylic resin, an acrylate resin, an epoxy acrylateresin, or a combination thereof. In an embodiment, the size coatcomposition can comprise a reinforcing additive, such as amorphoussilica. In a specific embodiment, the size coat composition can comprisea cycloaliphatic epoxy resin, an epoxide, a diepoxide, a butanediol, atriacrylate, a hexaacrylate, a cyclohexylcarboxylate, or a combinationthereof. In a specific embodiment, the size coat composition cancomprise a silica reinforced cycloaliphatic epoxy resin, an aliphaticepoxidized butanediol, trimethylolpropane triacrylate (TMPTA),dipentaerythritol hexaacrylate (DPHA), (3,4-epoxycyclohexane) methyl3,4-epoxycyclohexylcarboxylate, or a combination thereof.

In a specific embodiment, the size coat composition can include 5 wt %to 45 wt % of a reinforcing filler, such 10 wt % to 35 wt % of areinforcing filler.

Supersize Coat Composition

As previously described, the coated abrasive article 100 can optionallycomprise a layer of supersize coat composition (not shown) disposed onthe size coat composition 119. The supersize coat composition can be thesame as or different from the polymeric binder composition 115 of theabrasive layer 103 and can be same as or different than the size coatcomposition 119 disposed thereon. In another aspect, the supersize coatcomposition may comprise an anti-loading agent (such as a stearate, suchas a metal stearate, such as zinc stearate or calcium stearate) or agrinding aid (such as cryolite, potassium borofluorate), or acombination thereof.

Additives

In a particular aspect, the front coat composition 111, the back coatcomposition 113, the binder composition 115, the size coat composition119, or the supersize coat composition (not shown) can include one ormore additives. Additives can be available in an amount of 0 wt % to 10wt % of any polymer layer (i.e., make coat layer, size coat layer, orsupersize layer). Suitable additives, for example, can include grindingaids, fibers, lubricants, wetting agents, thixotropic materials,surfactants, thickening agents, pigments, dyes, antistatic agents,coupling agents, plasticizers, suspending agents, pH modifiers, adhesionpromoters, lubricants, bactericides, fungicides, flame retardants,degassing agents, anti-dusting agents, dual function materials,initiators, chain transfer agents, stabilizers, dispersants, reactionmediators, colorants, and defoamers. The amounts of these additivematerials can be selected to provide the properties desired. Theseoptional additives can be present in any part of the overall system ofthe coated abrasive product according to embodiments of the presentdisclosure. Suitable grinding aids can be inorganic based; such ashalide salts, for example cryolite, wollastonite, and potassiumfluoroborate; or organic based, such as sodium lauryl sulphate, orchlorinated waxes, such as polyvinyl chloride. In an embodiment, thegrinding aid can be an environmentally sustainable material.

EMBODIMENTS Embodiment 1

An abrasive belt comprising: an abrasive film having a joint; whereinthe abrasive film comprises an abrasive layer disposed on a backingmaterial; wherein the backing material comprises: a backing substratehaving a first side and a second side; and a back coat disposed on thesecond side of the backing substrate; and wherein the joint comprises: afirst end of the abrasive film abutting a second end of the abrasivefilm; a polymeric joint adhesive disposed on the back coat of the firstend and the back coat of the second end; and a joint tape disposed overthe polymeric joint adhesive.

Embodiment 2

The abrasive belt of embodiment 1, further comprising a Triple Head Testrating of at least 10 minutes, such as at least 15 minutes, at least 20minutes, or at least 30 minutes.

Embodiment 3

The abrasive belt of embodiment 1, wherein the back coat comprises alayer of a polymeric acrylate composition.

Embodiment 4

The abrasive belt of embodiment 3, wherein the polymeric acrylatecomposition comprises an ethyl acrylate, an ethylene acrylate, anethylene-methyl acrylate, an ethylene-ethyl acrylate, or a combinationthereof.

Embodiment 5

The abrasive belt of embodiment 4, wherein the layer of polymericacrylate composition comprises a thickness of at least 0.1 mil to notgreater than 3 mil, such as at least 0.25 mil to not greater than 2.5mil, or at least 0.5 mil to not greater than 2 mil.

Embodiment 6

The abrasive belt of embodiment 1, further comprising a front coatdisposed on the first side of the backing substrate between the abrasivelayer and the backing substrate.

Embodiment 7

The abrasive belt of embodiment 6, wherein the front coat comprises alayer of a polymeric ethylene composition.

Embodiment 8

The abrasive belt of embodiment 7, wherein the polymeric polyethylenecomposition comprises a low-density polyethylene, a high-densitypolyethylene, or a combination thereof.

Embodiment 9

The abrasive belt of embodiment 8, wherein the polymeric polyethylenecomposition comprises a thickness of at least 0.25 mil to not greaterthan 5 mil, such as at least 1 mil to not greater than 3 mil, or atleast 1.5 mil to not greater than 2.5 mil.

Embodiment 10

The abrasive belt of embodiment 1, wherein the backing substratecomprises a polymeric film.

Embodiment 11

The abrasive belt of embodiment 10, wherein the polymeric film comprisesa polyester film.

Embodiment 12

The abrasive belt of embodiment 10, wherein the polymeric film comprisespolyethylene terephthalate.

Embodiment 13

The abrasive belt of embodiment 10, wherein the polymeric film comprisesa thickness of at least 1 mil to not greater than 10 mil, such as atleast 2 mil to not greater than 8 mil, at least 3 mil to not greaterthan 7 mil, or at least 4 mil to not greater than 6 mil.

Embodiment 14

The abrasive belt of embodiment 10, wherein the polymeric film comprisesa surface energy of at least 40 dyne/cm2, such as at least 45 dyne/cm2,as at least 50 dyne/cm2, as at least 55 dyne/cm2.

Embodiment 15

The abrasive belt of embodiment 14, wherein the polymeric film is coronatreated.

Embodiment 16

The abrasive belt of embodiment 15, wherein the corona treatmentincreases the surface energy 5 to 50 dyne/cm2, such as 10 to 35dyne/cm2.

Embodiment 17

The abrasive belt of embodiment 1, wherein the joint comprises a buttjoint.

Embodiment 18

The abrasive belt of embodiment 17, wherein the joint includes a surfaceenergy treatment in a region adjacent the joint.

Embodiment 19

The abrasive belt of embodiment 18, wherein the surface treatmentincreases the surface energy by 10-30 Dynes/cm2.

Embodiment 20

The abrasive belt of embodiment 18, wherein the surface treatmentcomprises a corona treatment, a plasma treatment, or a combinationthereof.

Embodiment 21

The abrasive belt of embodiment 1, wherein the abrasive layer comprisesa polymeric make coat composition and abrasive particles disposed in themake coat composition.

Embodiment 22

The abrasive belt of embodiment 21, wherein the make coat compositioncomprises an epoxy acrylate polymer, an epoxy methacrylate polymer, abutyl acrylate polymer, or a combination thereof.

Embodiment 23

The abrasive belt of embodiment 21, wherein the make coat compositionfurther comprises a filler.

Embodiment 24

The abrasive belt of embodiment 21, wherein the abrasive layer furthercomprises a polymeric size coat composition disposed on the make coatcomposition and abrasive particles.

Embodiment 25

The abrasive belt of embodiment 21, wherein the size coat compositioncomprises an epoxy acrylate polymer, an epoxy methacrylate polymer, abutyl acrylate polymer, or a combination thereof.

Embodiment 26

The abrasive belt of embodiment 21, wherein the make coat compositionfurther comprises a filler.

Embodiment 27

The abrasive belt of embodiment 21, wherein the abrasive particlescomprise diamond, cubic boron nitride, or a combination thereof.

Embodiment 28

The abrasive belt of embodiment 21, wherein the abrasive particlescomprise a grit size of 10 microns to 500 microns.

EXAMPLES Example 1.—Sample Coated Abrasive Belt Preparation

A sample coated abrasive film belt was prepared as described herein. Ina first step, a backing material was prepared by applying a front coatand a back coat to a backing substrate. Details of the backing materialare provided below in Table 1. The completed backing material was storedfor later use.

TABLE 1 Backing Material S1 Front Coat Low density polyethylene BackingPolymer film¹, primed², and corona treated³ Substrate Back CoatCopolymer Blend 90-95 wt % ethylene and butyl acrylate copolymer 05-10wt % ethylene acrylic ester terpolymer⁵ ¹Chemically treated PET film, 5mil thick ²Primer - polyethylene imine ³50-60 dyne/cm², both sides⁴Lotryl, Arkema, Inc. ⁵Lotader, Arkema, Inc.

The prepared backing material was then used to make a sample coatedabrasive film as described herein. A make coat was applied to thebacking material wherein the make coat was disposed onto the front coatof the backing material. Abrasive particles were disposed on the makecoat and a size coat was applied over the make coat and abrasiveparticles. Details of the make coat, abrasive particles, and size coatare provided below in Table 2. The completed coated abrasive film wasstored as a jumbo roll for later use.

TABLE 2 Coated Abrasive Film S1 Size Coat UV curable copolymer blend40-65 wt % epoxy resin 3⁹ 10-20 wt % epoxy resin 4¹⁰ 1-10 wt % acrylateresin 2¹¹ 0-5 wt % acrylate resin 3¹² 0-5 wt % epoxy acrylate resin¹³10-20 wt % filler¹⁴ Abrasive Metal bond diamond, 65-75 micron ParticlesMake Coat UV curable copolymer blend 55-75 wt % epoxy resin 1⁶ 05-12 wt% epoxy resin 2⁷ 10-20 wt % oxetane 1-08 wt % acrylate resin⁸⁶Diphenylolpropane (DPP) resin - Eponex ⁷Bisphenol A Epoxy Diacrylate -Ebecryl ⁸Propoxylated neopentyl glycol diacrylate - Sartomer ⁹Silicareinforced cycloaliphatic epoxy resin (Nanopox) ¹⁰Aliphatic epoxidizedbutanediol (Erisyg) ¹¹Trimethylolpropane triacrylate (TMTPA)¹²Dipentaerythritol hexaacrylate (DPHA) ¹³methyl3,4-epoxycyclohexylcarboxylate ¹⁴Amorphous silica

Example 2.—Sample Abrasive Belt Preparation

Sample coated abrasive film belts were prepared as described herein.Sample coated abrasive polishing film as prepared above in Example 1 wasobtained from a jumbo roll and slit (i.e., cut) into a plurality of 10in×30 in panels, which were then used to make sample abrasive filmbelts.

A corona surface treatment was first applied to each end of thepolishing film panels using a hand held corona treatment unit (ElectroTechnic Products, Inc.) with a round electrode. Four passes of thecorona treatment unit were made along the edge of the end of each panel.The electrode distance was ⅛ inch to ¼ inch away from the abrasive filmduring treatment. Prior to corona treatment, the initial surface energyof each of the abrasive film ends was about 30-32 dyne/cm². After coronatreatment, the final surface energy of each of the abrasive film endswas about 40-62 dyne/cm², typically 45-60 dyne/cm² (an increase of 10-30dyne/cm²). A joint adhesive (a hot melt polyurethane adhesivecomposition) was applied with a roller to the back coat of each end ofthe abrasive film. The ends were brought together to form a butt jointand a polymer film joint tape was applied over the joint and the jointadhesive in the region around the joint. Heat (190° F.) and pressure(800 lbf) were applied (5 sec.) using a belt joiner press to completethe joint and form the abrasive belt.

Example 3.—Sample Abrasive Film Belt Testing

Sample coated abrasive film belts S1 and comparative abrasive film beltsC1 and C2 were prepared as described herein. The details of the abrasivebelts are provided in Table 3. The construction of the sample andcomparative belts was the same except as indicated in Table 3. Thesample and comparative abrasive film belts were subjected to testing(Triple Head Test—30 psig; 0.5 IN Spindle; 30 minutes max. duration) toevaluate the strength and durability of the abrasive film belts andtheir joints. The testing results are shown in Table 3.

TABLE 3 Backing Material S1 C1 C2 Backing Polymer film Same as S1 Sameas S1 Substrate (see Example 1 above) Back Coat Ethylene acrylate Sameas S1 Low density copolymer blend polyethylene (see Example 1 above)Corona Yes — Same as S1 Treatment (see example 2 above) Joint adhesiveHot Melt Same as S1 Same as S1 Polyurethane (see example 2 above) JointTape Yes Same as S1 Same as S1 (see example 2 above) Triple Head TestFull Pass Partial Pass Fail Overall Result Triple Head Test +30 minutes12.3 minutes 0.1 minutes Avg. Time to Max. duration Failure reached

Significantly, all sample abrasive film belts S1 did not break andreached the 30-minute maximum duration of the test.

Example 4.—Sample Abrasive Film Belt Testing

A polishing lathe having a 3 horsepower motor that turns a workpiece atspeeds of 1 to 100 revolutions per minute utilizes a belt size of2″×120″ and a maximum part length of 360″. Sample coated abrasive filmbelts S1 and comparative abrasive film belts C1 were run as slack ofbelt using no supporting wheel. The workpiece (e.g., rotor) was formedfrom stainless steel and had a High Velocity Oxygen Fuel (HVOF) spraycoating applied to the rotor at a thickness between 0.008″ and 0.015″depending on the base surface. The rotors typically take 15 to 18 hoursto finish. Sample abrasive film belt S1 showed a 20% performance boostand finished 100 inches of the rotor, while comparative abrasive filmbelt C1 only finished 80″ of the rotor. The results are shown in FIG. 5. Sample abrasive film belt S1 also showed a 25% better surface finish.

Example 5.—Sample Abrasive Film Belt Testing

A polishing lathe having a 3 horsepower motor that turns a workpiece atspeeds of 1 to 100 revolutions per minute utilizes a belt size of2″×120″ and a maximum part length of 360″. Sample coated abrasive filmbelts S1 and comparative abrasive film belts C1 were used in conjunctionwith a 6″ rubber contact roll in the polishing lathe. The workpiece(e.g., rotor) was formed from stainless steel and had a High VelocityOxygen Fuel (HVOF) spray coating applied to the rotor at a thicknessbetween 0.010″ and 0.025″ depending on the base surface. Sample abrasivefilm belt S1 finished 120 inches of the rotor, while comparativeabrasive film belt C1 only finished 60″ of the rotor. The results areshown in FIG. 6 .

In the foregoing, reference to specific embodiments and the connectionsof certain components is illustrative. It will be appreciated thatreference to components as being coupled or connected is intended todisclose either direct connection between said components or indirectconnection through one or more intervening components as will beappreciated to carry out the methods as discussed herein. As such, theabove-disclosed subject matter is to be considered illustrative, and notrestrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Moreover, not all of theactivities described above in the general description or the examplesare required, that a portion of a specific activity cannot be required,and that one or more further activities can be performed in addition tothose described. Still further, the order in which activities are listedis not necessarily the order in which they are performed.

The disclosure is submitted with the understanding that it will not beused to limit the scope or meaning of the claims. In addition, in theforegoing disclosure, certain features that are, for clarity, describedherein in the context of separate embodiments, can also be provided incombination in a single embodiment. Conversely, various features thatare, for brevity, described in the context of a single embodiment, canalso be provided separately or in any subcombination. Still, inventivesubject matter can be directed to less than all features of any of thedisclosed embodiments.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that cancause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

Thus, to the maximum extent allowed by law, the scope of the presentinvention is to be determined by the broadest permissible interpretationof the following claims and their equivalents, and shall not berestricted or limited by the foregoing detailed description.

What is claimed is:
 1. An abrasive belt comprising: an abrasive filmhaving a joint; wherein the abrasive film comprises an abrasive layerdisposed on a backing material; wherein the backing material comprises:a backing substrate having a first side and a second side; and a backcoat disposed on the second side of the backing substrate; wherein theback coat comprises a layer of a polymeric acrylate composition with athickness of at least 0.1 mil to not greater than 3 mil, wherein thepolymeric acrylate composition comprises an ethyl acrylate, an ethyleneacrylate, an ethylene-methyl acrylate, an ethylene-ethyl acrylate, or acombination thereof; and wherein the joint comprises: a first end of theabrasive film abutting a second end of the abrasive film; a polymericjoint adhesive disposed on the back coat of the first end and the backcoat of the second end; and a joint tape disposed over the polymericjoint adhesive.
 2. The abrasive belt of claim 1, further comprising: aTriple Head Test rating of at least 10 minutes.
 3. The abrasive belt ofclaim 1, wherein the polymeric acrylate composition comprises anethylene acrylate.
 4. The abrasive belt of claim 3, wherein thepolymeric acrylate composition comprises an ethyl acrylate.
 5. Theabrasive belt of claim 4, wherein the polymeric acrylate compositioncomprises a thickness of at least 0.25 mil to not greater than 2.5 mil.6. The abrasive belt of claim 1, further comprising: a front coatdisposed on the first side of the backing substrate between the abrasivelayer and the backing substrate.
 7. The abrasive belt of claim 6,wherein the front coat comprises a layer of a polymeric polyethylenecomposition.
 8. The abrasive belt of claim 7, wherein the polymericpolyethylene composition comprises a low-density polyethylene, ahigh-density polyethylene, or a combination thereof.
 9. The abrasivebelt of claim 8, wherein the polymeric polyethylene compositioncomprises a thickness of at least 0.25 mil to not greater than 5 mil.10. The abrasive belt of claim 1, wherein the backing substratecomprises a polymeric film formed from at least one of polyester andpolyethylene terephthalate.
 11. The abrasive belt of claim 10, whereinthe polymeric film comprises a thickness of at least 1 mil to notgreater than 10 mil.
 12. The abrasive belt of claim 10, wherein thepolymeric film comprises a surface energy of at least 40 dyne/cm². 13.The abrasive belt of claim 12, wherein the polymeric film is coronatreated, and wherein the corona treatment increases the surface energy 5to 50 dyne/cm².
 14. The abrasive belt of claim 1, wherein the jointcomprises a butt joint.
 15. The abrasive belt of claim 14, wherein thejoint includes a surface energy treatment comprising a corona treatment,a plasma treatment, or a combination thereof, in a region adjacent thejoint, and wherein the surface treatment increases the surface energy by10-30 Dynes/cm².
 16. The abrasive belt of claim 1, wherein the abrasivelayer comprises a polymeric make coat composition and abrasive particlesdisposed in the make coat composition.
 17. The abrasive belt of claim16, wherein the abrasive layer further comprises a polymeric size coatcomposition disposed on the make coat composition and abrasiveparticles.
 18. The abrasive belt of claim 17, wherein at least one ofthe make coat composition and the size coat composition comprises anepoxy acrylate polymer, an epoxy methacrylate polymer, a butyl acrylatepolymer, or a combination thereof.
 19. The abrasive belt of claim 16,wherein the abrasive particles comprise diamond, cubic boron nitride, ora combination thereof.
 20. The abrasive belt of claim 19, wherein theabrasive particles comprise a grit size of 10 microns to 500 microns.